Gas control method for a hybrid tankless water heater

ABSTRACT

An on demand tankless water heater system that is capable of quickly delivering water within a desired temperature range. The tankless water heater provides a hybrid heating method that contains a primary heating system and a secondary heating system disposed in a buffer tank that cooperate to facilitate control of output water temperature during water usage. A pressure differential switch detects low flow demand and allows the secondary heating system to provide immediate heating to the water. This secondary heating system provides a faster temperature response and fine tuning of output water temperature.

PRIORITY CLAIM AND RELATED APPLICATIONS

This divisional patent application claims the benefit of priority fromprovisional application U.S. Ser. No. 61/149,418 filed on Feb. 3, 2009and U.S. Ser. No. 12/692,628 filed on Jan. 24, 2010. Each of saidapplications is incorporated by reference in its entirety.

FIELD OF INVENTION

This invention relates to apparatus and control methods for waterheaters, and more specifically, to hybrid tankless water heaters.

BACKGROUND ART

Most water heaters are capable of delivering water at a desiredtemperature in steady state conditions where the water demand or flowrate is substantially constant. However, water heating systems presentlyavailable or prior art water heating systems fall short when attemptingto maintain a water output at a constant predetermined temperature levelduring rapid shifts or fluctuations in water demand. It is understoodthat the demand for water is directly related to the output flow raterequested from the water heating system. Prior art water heating systemswill provide the water output flow rate corresponding to the waterdemand placing the predetermined temperature setting as a secondaryconsideration. Placing predetermined water output temperature as asecondary consideration creates two major thermal related problems. Thefirst issue is encountered during a rapid increase in water demand,wherein the user or device experiences a sudden drop in watertemperature or a cold water splash. The remaining issue occurs during arapid decrease in water demand, wherein the user or device experiences asudden spike in water temperature, thereby creating a possible burn orscald type hazard. Furthermore, none of the prior art water heaters arecapable of delivering water at the predetermined or desired temperaturerange without substantial delays. The rapid shifts in water demandcreates a transient condition within the water heating system whereinsuch existing systems are ill equipped to handle.

On-demand water heaters are gaining popularity because of their reducedspace requirement in addition to improved energy advantages. The currenton-demand water heaters have well known drawbacks, most notably, theuncontrollable and undesirable fluctuation of temperature of the outputwater during water usage. When output water flow increases, thetemperature of the output water decreases. Conversely, when output waterflow decreases, the temperature of the output water increases. Thiscreates undesirable temperature fluctuations for users, appliances, andthe like. Disadvantages of these tankless water heaters are well knownin the art and general population, such a discussion is described inWikipedia, and reads as follows:

-   -   Installing a tankless system comes at an increased cost,        particularly in retro-fit applications. They tend to be        particularly expensive in areas such as the US where they are        not dominant, compared to the established tank design. If a        storage water heater is being replaced with a tankless one, the        size of the electrical wiring or gas pipeline may have to be        increased to handle the load and the existing vent pipe may have        to be replaced, possibly adding expense to the retrofit        installation. Many tankless units have fully modulating gas        valves that can range from as low as 10,000 to over 1,000,000        BTUs. For electrical installations (non-gas), AWG 10 or 8 wire,        corresponding to 10 or 6 mm², is required for most POU (point of        use) heaters at North American voltages. Larger whole house        electric units may require up to AWG 2 wire. In gas appliances,        both pressure and volume requirements must be met for optimum        operation.    -   There is a longer wait to obtain hot water. A tankless water        heater only heats water upon demand, so all idle water in the        piping starts at room temperature. Thus there is a more apparent        “flow delay” for hot water to reach a distant faucet.    -   There is a short delay between the time when the water begins        flowing and when the heater's flow detector activates the        heating elements or gas burner. In the case of continuous use        applications (showers, baths, washing machine) this is not an        issue. However, for intermittent use applications (for example        when a hot water faucet is turned on and off repeatedly) this        can result in periods of hot water, then some small amount of        cold water as the heater activates, followed quickly by hot        water again. The period between hot/cold/hot is the amount of        water which has flowed though the heater before becoming active.        This cold section of water takes some amount of time to reach        the faucet and is dependent on the length of piping.    -   Since a tankless water heater is inactive when hot water is not        being used, they are incompatible with passive        (convection-based) hot water recirculation systems. They may be        incompatible with active hot water recirculation systems and        will certainly use more energy to constantly heat water within        the piping, defeating one of a tankless water heater's primary        advantages.    -   Tankless water heaters often have minimum flow requirements        before the heater is activated, and this can result in a gap        between the cold water temperature, and the coolest warm water        temperature that can be achieved with a hot and cold water mix.    -   Similarly, unlike with a tank heater, the hot water temperature        from a tankless heater is inversely proportional to the rate of        the water flow—the faster the flow, the less time the water        spends in the heating element being heated. Mixing hot and cold        water to the “right” temperature from a single-lever faucet        (say, when taking a shower) takes some practice. Also, when        adjusting the mixture in mid-shower, the change in temperature        will initially react as a tanked heater does, but this also will        change the flow rate of hot water. Therefore some finite time        later the temperature will change again very slightly and        require readjustment. This is typically not noticeable in        non-shower applications. A temperature compensating valve tends        to eliminate this issue. Tankless systems are reliant on the        water pressure that is delivered to the property. In other        words, if a tankless system is used to deliver water to a shower        or water faucet, the pressure is the same as the pressure        delivered to the property and cannot be increased, whereas in        tanked systems the tanks can be positioned above the water        outlets (in the loft/attic space for example) so the force of        gravity can assist in delivering the water, and pumps can be        added into the system to increase pressure. Power showers, for        example, cannot be used with tankless systems because it cannot        deliver the hot water at a fast enough flow-rate required by the        pump.

A typical water demand scenario is provided in the following example. Afirst user draws water at a desired temperature at a bathroom faucetwhile simultaneously a second user opens a kitchen faucet. The outputwater temperature experienced by both users dramatically decreases sincethe total flow rate through the water heater increases, and thus, thevolume of water to be heated per unit of time has increased while theburner output remains constant (or the system is not capable of keepingpace with the increased water demand). At the other end of the spectrum,in a situation where two users are using water at desired temperature attwo separate faucets, where one user closes a faucet, the remaining openfaucet will experience a spike (dramatic increase) in temperature. Thisis due to a decrease in the volume of water to be heated per unit timeresulting in a reduction of water flow through the water heaterresulting in an increase in output water temperature.

Other well known drawbacks associated current on demand water heatersinclude the cold sandwich effect, freeze hazards, and dead zones.Controls for water heaters are plagued with limitations and lack thesophistication to maximize system efficiency.

The purpose of the present invention is to overcome several shortcomingsin the aforementioned prior art as well as the introduction ofadditional novel features.

SUMMARY OF THE INVENTION

The present invention overcomes the shortcomings of the prior art byproviding several new and novel structures and methods for an improvedhybrid tankless water heater. Briefly described, in a preferredembodiment, the improved hybrid tankless water heater overcomes theaforementioned prior art disadvantages, and better aligns with the needsand desires of a typical user by the addition of several subsystemsassemblies, one such subsystem includes a thermally insulated mixingbuffer tank disposed downstream from the heat exchanger located withinthe primary heating subsystem. The mixing buffer tank has turbulenceinducing baffles to facilitate mixing. There is further provided asecondary heating element to supply supplemental heat, preferablydisposed in the mixing buffer tank. Further provided is a differentialpressure switch that functions to rapidly detect trickle or low flowconditions and activate or pre-activate primary and/or secondary heatingelements depending on the detected real time water demand.Pre-activation shall be understood as a sensitive detection scheme thatpredicts usage given relatively small input signals. Also included is arecirculating system, and an inverted burner system in the primaryheating subsystem comprising an array of coiled tubing surrounding anaxially disposed radial burner, and a buffer tank which forms the coreplug at exit end of the coil tubing forcing heated air drawn in from theentry end of the coil tubing to surround the exit end of the coil tubingeffectively transferring heat to the water flowing inside the coiltubing.

One aspect of the novel controls method of the present inventionincludes receiving inputs, such as pressure differential to detect lowflow levels and has outputs that eliminate hunting, allow fineadjustment of temperature, and prevent overshoot. Another aspect of thenovel control method of the present invention maintains water at apredetermined target temperature, e.g. above 33 degrees Fahrenheit, byre-circulating, initiating a secondary electric heating element, pulsefiring the burner of a primary heating element, or any combinationthereof. There is provided a controller comprising a processor, memoryand software for managing the outlet temperature to a desiredtemperature corresponding to given portions within a given day, week, orthe like.

It is an object of the present invention to minimize variation of thewater heater's predetermined outlet temperature regardless of rapidshifts or fluctuations in water demand.

It is another object of the present invention to minimize delaysassociated with achieving predetermined target temperatures at the waterheater output.

It is yet another object of the present invention to minimize oreliminate the cold sandwich effects in transient system situations.

It is yet another object of the present invention to minimize oreliminate dead zones (conditions where water flow is below detectionusing typical sensing means) in a transient system.

It is yet another object of the present invention to minimize oreliminate the problem of bacteria growth in stored water supplies andwater system components.

It is yet another object of the present invention to provide a method ofcontrolling temperature and water flow in a water heater to maximizeefficiency and response time.

It is yet another object of the present invention to provide fineheating modulation.

It is yet another object of the present invention to minimize or avoidboth firing and transient delays.

It is yet another object of the present invention to minimize oreliminate freeze hazards.

It is yet another object of the present invention to actively monitorand detect system leaks.

It is yet another object of this invention to provide a hybrid tanklesswater heater that is relatively economical from the viewpoint of themanufacturer and consumer, is susceptible to low manufacturing costswith regard to labor and materials, and which accordingly is thensusceptible of low prices for the consuming public, thereby making iteconomically available to the buying public.

Whereas there may be many embodiments of the present invention, eachembodiment may meet one or more of the foregoing recited objects in anycombination. It is not intended that each embodiment will necessarilymeet each objective.

In this respect, before explaining at least one embodiment of theinvention in detail, it is to be understood that the invention is notlimited in its application to the details of construction and thearrangements of the components set forth in the following description orillustrated in the drawings. The present invention is capable of otherembodiments and of being practiced and carried out in various ways.Thus, having broadly outlined the more important features of the presentinvention in order that the detailed description thereof may be betterunderstood, and that the present contribution to the art may be betterappreciated, there are, of course, additional features of the presentinvention that will be described herein and will form a part of thesubject matter of this specification.

PARTICULAR ADVANTAGES OF THE INVENTION

The present invention provides an apparatus and method for minimizingvariation of the water heater's predetermined outlet temperatureregardless of rapid shifts or fluctuations in water demand by disposinga buffer tank downstream from the primary heat exchanger. Delayedtemperature response as well as temperature fluctuations at the waterheater's output is minimized by providing supplemental heat (providedfrom an energy source other that natural gas) via a secondary heatingelement. This secondary heating element also provides fine heatingmodulation. Temperature response delays are also minimized by providinga means to rapidly detect conditions that require additional sources ofheat to the water heater. The problem of dead zones (conditions wherewater flow is below detection using typical prior art sensing means) issolved by utilizing a means to detect trickle, low-level, or low flowfollowed by activating a secondary heating element associated with arecirculation path, circuit, or watercourse from which the output of thewater heater can tap into. In the present invention, detecting trickleflow or low flow rapidly is accomplished by using a differentialpressure switch. By controlling outlet temperature to a desiredtemperature at set time periods in a day, the present inventionadvantageously avoids both firing and transient delays. The presentinvention also minimizes the cold sandwich effect in a transient systemby mixing the fluid in the buffer tank via recirculation. The presentinvention optionally includes an antibacterial hot water flush mode thatinhibits bacteria growth and/or sanitizes stored water supplies andwater system components. This is accomplished by recirculation of outletflow and maintaining water temperature at an elevated temperature for apredetermine period of time capable of killing off the target microbes,for example, 140 degrees Fahrenheit for 20 minutes. Water freezinghazards are minimized by actively maintaining water at above freezingtemperatures by re-circulating and activating a secondary electric heatsource and/or pulse firing the burner of the primary heat source (e.g.vacation mode). Transient temperature spikes are reduced by means ofcontrolling a blower that operates independent of the burner and arecirculation pump. There is provided baffles or a barrel-hole styleinlet system for creating turbulence and promoting mixing of theincoming water with existing water in the buffer tank.

By mounting the flow sensor outside of the recirculation circuit, thereis no pressure loss imparted by the flow sensor. This allows the use ofa pump with a lower power rating, thereby making the water heater moreeconomical. Additionally, no proprietary pump or flow sensor arerequired. Flue condensate backup or blockage is detected by using acondensate level sensor system. The present invention optionallyincludes a feature that enables a user to set or program an automatictemperature rise rate and a high temperature limit. A baffle mixespre-combusted air in the vicinity of the heat exchanger, therebypromoting heat transfer from the exterior surfaces of the heat exchangerto the pre-combusted air and recovering this absorbed heat of thepre-combusted air by redistributing it to colder portions of the heatexchanger surfaces.

User maintenance is facilitated by decoding fault code(s) and optionallyproviding audible or text speech corrective procedures. Active andcontinuous monitoring performance and health of the water heater, andautomatic adjustment of operating parameters, minimizes unforeseenservice shutdowns.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described by reference to the specification andthe drawings, in which like numerals refer to like elements, andwherein:

FIG. 1 is one embodiment of a hot water heater system of the presentinvention;

FIG. 2 is a schematic block diagram of a preferred embodiment of a waterheater controller of the water heater system of FIG. 1;

FIG. 3 is a schematic controls diagram of the water heater controller;

FIG. 4 depicts an alternate embodiment of a water heater;

FIG. 5 depicts an alternate embodiment of a water heater;

The drawings are not to scale, in fact, some aspects have beenemphasized for a better illustration and understanding of the writtendescription. For simplicity in representing the complex controls scheme,the diamonds in the block figures schematically represent input and/oroutput devices. Arrows pointing toward a diamond represent inputdevices, arrows pointing away from a diamond represent output devicesand arrows both pointing toward and away from a diamond represent a dualinput-output device.

PARTS LIST

-   2—hot water heater-   4—hot water heater enclosure-   6—flow path-   8—primary heating system (burner including heat exchanger)-   9—primary heating process-   10—inlet of water heater-   11—inlet flow-   12—outlet flow-   13—mixed flow for second point of demand-   14—thermal insulation for mixing buffer tank-   15—mixing buffer tank-   16—secondary heating element (electric heater)-   17—secondary heating process-   18—inlet temperature sensor-   19—external auxiliary device circuit-   21—mixed flow (for second point of demand)-   22—outlet temperature sensor-   23—outlet temperature sensor for auxiliary demand-   24—flow limiting valve-   25—internal recirculating flow circuit-   26—flow sensor-   27—external recirculating flow circuit-   28—recirculation pump-   29—blower speed feedback-   30—internal recirculation check valve-   31—portion of recirculation flow-   32—internal recirculating flow-   33—external recirculation check valve-   34—burner-   35—internal recirculation modulating valve-   36—blower-   36 a—blower fan speed control-   37—external recirculation modulating valve-   37 a—external recirculation flow-   38—controller-   39—temperature sensor (merged flow)-   40—flue gas exit-   41—merged flow temperature signal-   42—expansion tank-   43—user interface-   44—bypass flow (buffer tank)-   45—buffer tank bypass line-   46—moisture sensor-   47—external auxiliary device modulating valve-   48—differential pressure switch-   50—condensate level sensor-   52—flue gas temperature sensor-   53—external gas usage input signal-   54—buffer tank flow-   56—buffer tank bypass three way valve-   59—auxiliary three way valve-   60—capillary bypass line-   61—distal end of the heat exchanger-   64—auxiliary heat sink-   66—first demand point-   67—cold water point of demand-   68—second demand point-   70—outlet temperature (T_(outlet))-   72—inlet temperature (T_(inlet))-   74—desired temperature (T_(desired))-   76—temperature difference (T_(desired)−T_(outlet))-   78—temperature difference (T_(desired)−T_(inlet))-   80—flow rate-   82—flue gas temperature-   84—flue gas temperature limit—flue gas temperature-   90—feedforward control-   92—feedback control-   94—main control-   96—safety control-   98—secondary heat control (electric heat)-   100—recirculation control-   102—flow limiting valve control-   104—differential pressure switch-   106—differential pressure signal-   108—flue temperature limit-   112—available power

Also it is to be understood that the phraseology and terminologyemployed herein are for the purpose of description and should not beregarded as limiting.

DEFINITIONS OF TERMS USED IN THIS SPECIFICATION

The term hybrid tankless water heating system shall have equivalentnomenclature including: the hybrid water heater, the heater, the device,the present invention, or the invention. As used in this specification,the following terms shall be defined as follows:

Hybrid water heater shall mean a water heater that combines two heatingmeans, via a primary heating element and a secondary heating element,such as a gas burner and an electric immersion coil.

Usage is defined as units of “damage.”

“Damage” is a quantity of usage as seen in a water heater. “Damage” caninclude the effects of scaling, wear, burner cycles, amount of waterdelivered, etc. An increased usage of a water heater causes acorresponding increase in the amount of “damage.”

The efficiency of a water heating system is defined as the amount ofconverted thermal energy in the delivered water per unit of energyinput. The efficiency of a water heater system is typically nonlinearwith respect to flow rate.

Additionally, the term “exemplary” shall possess only one meaning inthis disclosure; wherein the term “exemplary” shall mean: serving as anexample, instance, or illustration.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT

FIG. 1 illustrates one embodiment of a novel hybrid tankless waterheater 2 (“water heater”) and the relative placement of variouscomponents of the system. Briefly described, the water heater 2comprises an enclosure 4 having a thermally insulated mixing buffer tank15 with baffles disposed downstream from a heat exchanger of a primaryheating system 8. There is further provided a secondary heating element16 to supply supplemental heat, preferably disposed in mixing buffertank 15. The combination of two heating systems (such as gas andimmersion electric) thus renders the present invention a “hybrid” waterheater.

Optionally there is further provided a differential pressure switch 48that functions to rapidly detect a need to turn on primary 8 orsecondary 16 heating elements by detecting trickle or low flow. There isalso provided an internal recirculating system 25 and an inverted burnersystem in primary heating system 8. The differential pressure switch isan important feature of the present invention in that it provides ameans for fine controlling of output water temperature, a means forexpedient temperature response to a demand, and a means for detectingleakage and activating associated alarms or alerts.

Other embodiments may include advantageous features described in greaterdetail below, including a moisture sensor in the enclosure, anintegrated buffer and expansion tank or an independent expansion tank, acondensate level sensor, a capillary bypass line, a blower that operatesindependent of the burner and recirculation pump, and a feature thatallows the user to set an automatic temperature rise rate and a hightemperature limit. Yet other additional advantageous features areprovided and described herein, including features to enhance userability for self-maintenance of the water heater.

A demand at first demand point 66 causes a fluid flow to enter the waterheater 2 at inlet 10 and exit water heater 2 at outlet 12. In theillustrative embodiment, water at first demand point 66 is not mixedwith cold incoming water upon receiving heat from system heat sources(e.g., primary heating element 9 and secondary heating element 16),however, it is contemplated that water at first demand point 66 may bemixed with a cold water supply via a three way valve connection or othersimilar mechanism.

Continuing to refer to FIG. 1, water heater 2 includes a flow limitingvalve 24 for restricting inlet flow 11. The flow limiting valve 24controls the flow rate of water entering the water heater 2. Waterheater 2 further includes an inlet water temperature sensor 18 to sensethe inlet water temperature.

The internal recirculating flow circuit 25 facilitates an internalrecirculating flow 32 that is merged with the inlet flow 11. Thisinternal recirculating flow circuit 25 includes an internalrecirculation modulating valve 35 and a check valve 30. Check valve 30permits recirculation from outlet 12 end of water heater 2 to inlet 10end and stops any flow from inlet 10 end to outlet 12 end of waterheater 2 while the internal recirculation modulating valve 35 modulatesthe magnitude of internal recirculation flow 32 in a predeterminedfashion.

The external recirculating flow circuit 27 comprises an externalrecirculation modulating valve 37 that modulates the magnitude ofexternal recirculation flow 37 a. Flow circuit 27 includes an externalrecirculation check valve which permits only the flow of water from theheated outlet via the external cold water supply line back to the inletof the heated, and a cold water point of demand 67 attached thereon.

Continuing to refer to FIG. 1, the inlet water temperature sensor 18 isplaced upstream of the point where internal recirculating flow 32 andwater flow from inlet 10 converge. The water heater 2 preferablyincludes a flow sensor 26 that is disposed upstream from the point wherethe internal recirculating flow 32 and water flow from inlet 10converge. Temperature sensor 39 is placed at this point of convergence.

The water heater 2 has a primary heating element 9. In the embodimentdepicted in FIG. 1, primary heating system 8 comprises a burner 34, ablower 36, a fuel supply valve, and a heat exchanger. The heat exchangertransfers heat from the burner 34 to the water flow. Preferably, theblower 36 is used in conjunction with the burner 34 to enhance mixing ofthe fuel with ambient air prior to combustion. The blower 36 can alsoenhance convectional heat transfer by forcing the hot flue gas to distalend of the heat exchanger 61 from burner 34.

Upon passing through the heat exchanger, the heated water enters amixing buffer tank 15. The mixing buffer tank 15 serves as a reservesupply of warm water to ease excessively cold or warm water duringtransience. Preferably, mixing buffer tank 15 contains a secondaryheating system. An immersion heating element is beneficial in thisapplication. In the embodiment depicted, an electrical heating coil isused as a secondary heating element 16. When water flow at first demandpoint 66 exists, the flow from mixing buffer tank 15 can exit outlet 12and/or it can recirculate. The water heater 2 can include outlettemperature sensor 22 at outlet 12 of the water heater 2. A decrease intemperature as indicated by outlet temperature sensor 22 over time canbe used to detect a small flow.

A typical flow sensor requires a minimum flow in order to startregistering a flow rate. However, a particular advantage is realizedwhen a differential pressure switch 48 is utilized to detect a low flowcondition such that it effectively covers the range of flow the flowsensor 26 is unable to detect. Specifically, flows greater than 0.005gpm can be detected with this arrangement. It is to be understood thatdifferential pressure sensors that detect pressure and flows greater orlower than 0.005 gpm can be suitably used with the present invention. Adetected flow causes primary heating element 9 and secondary heatingelement 16 to turn on and water to be recirculated in order to maintainthe desired outlet temperature.

Recirculation alone, or recirculation with heating, also prevents freezeand may be activated with or without the detection of a flow.Recirculation and heating may also be programmed to start at auser-specified regular interval for a user-specified duration using atimer, or the like. Alternatively, the program may be set according tolearned interval and duration. In a learning system, water usage datasuch as the time stamp and duration of a demand and the volume of waterdemanded is collected over time and analyzed. As a result, recirculationand heating can be automatically turned on to anticipate periods of highdemand. In addition to providing freeze prevention, automatic activationof recirculation and heating minimizes delays of temperature response toa demand.

When a large amount of hot water is abruptly demanded, buffer tank 15may not be capable of supplying the amount of hot water demanded. Abuffer tank bypass three way valve 56 is provided to give water heater 2the capability of supplying heated water directly to the point of use atthe desired temperature. When the use of buffer tank 15 is desired,buffer tank bypass three way valve 56 is controlled such that bypassflow 44 is ceased. Conversely, if bypass is desired, the buffer tankflow 54 is ceased.

Continuing to refer to FIG. 1, water heater 2 further comprises anexpansion tank 42. Fluid expands as it is heated, causing pressure inthe water heater flow system to rise. Inclusion of expansion tank 42provides a particular advantage in accommodating this fluid expansionand may be mounted any location in the fluid flow system whichexperiences fluid expansion. In another embodiment not shown, thefunction of an expansion tank is incorporated into the buffer tank 15,eliminating the need of an independent expansion tank. In theillustrative embodiment, expansion tank 42 is mounted at inlet 10 end ofwater heater 2.

FIG. 2 is a generalized block diagram of the water heater controller ofthe water heater 2 of FIG. 1 depicting the inputs and outputs tocontroller 38. At the heart of the water heater controller is generalpurpose controller 38, the comprehensive unit capable of receivingelectrical signals, for example from sensors and switches, performingcomputations based on the signals and outputting electrical controlsignals as a result of the computations to actuate certain electrical orelectro-mechanical components. In the present invention, controller 38receives a plurality of sensor inputs and outputs a plurality of controlsignals to perform water heating control.

Referring to FIG. 2, user interface 43 is depicted as a bi-directionalcommunication tool for a user to enter preferences manually orautomatically provide control inputs from a second control device. Userinterface 43 also functions as a display for pertinent water heater 2information or to provide control output to a second control device.Flow sensor 26 provides flow rate to controller 38 indicating user hotwater demand from first demand point 66. In a system with multipledemand points, this flow rate could indicate the total flow rate of allof the demand points.

Outlet temperature sensor 22 provides a signal corresponding to thewater temperature at outlet 12 of water heater 2 of a water pipelineleading to first demand point 66. In a system with multiple demandpoints, there is provided an outlet temperature sensor 22 for eachoutlet.

Inlet water temperature sensor 18 provides a signal corresponding to thewater temperature at water heater inlet 10 of a water source.Preferably, moisture sensor 46 is mounted in the cavity of water heaterenclosure 4, and provides a signal corresponding to the humidity in thecavity of water heater enclosure 4. This provides a significantadvantage over the prior art in that a means for leak detection in theenclosure is provided. A differential pressure switch 48 provides asignal indicating the presence of a small demand from first demand point66 in the water heater 2. A condensate level sensor 50 provides a signalindicating whether the condensate resulting from the condensing heatexchanger is draining properly. This provides a significant advantageover the prior art in that it provides a means for corrosion control andpreventing overflow and the resulting mess. A flue gas temperaturesensor 52 provides a signal corresponding to the flue gas temperature.An excessive flue gas temperature or temperature rise rate causes thecontroller to de-rate the burner to avoid potentially unsafe operationdue to fire hazards and damage to the water heater 2. The means ofdetecting excessive heat is a significant advantage over the prior artby providing a manner to enhance safety and prevent equipment damage.

A control output is provided to control the water flow rate through thewater heater 2 via a flow limiting valve 24. A control output isprovided to control pump 28 speed. In one embodiment, the pump is asingle speed pump. A control output is provided to control fuel flowrate of burner 34. A burner 34 is immediately lit when fuel is admittedat the burner 34. If the fuel valve is opened and a flame is not litwithin a predetermined period of time (e.g., due to failed sparking orabsence of fuel flow), the fuel valve will be shut off and retried aftera predetermined period. A control output is provided to control a blower36 fan speed. The blower 36 fan is used in conjunction with burner 34 inorder to cause maximum heat transfer from burner 34 to the externalsurfaces of the heat exchanger. Blower 36 fan may also be turned onindependent of burner 34 such as in the case where heat loss is desiredof the heat exchanger tubes. Blower 36 speed control is further enhancedby the use of blower speed feedback 29.

A control output is provided to control the power output of a secondaryheating element 16, in this case, an electric heating element. Thiselectric heating element is used when the burner 34 is incapable ofachieving the heating response desired independently or when burner 34is incapable of providing a low heat rate. In one embodiment, the burnershutoff switch and the fuel shut off switch are a single integral switchunit. During low flow, the primary heating element (the burner) does notengage. When the flow is slightly above the level the secondary heatingelement (electric coil) can handle alone, pulse firing of the primaryheating element will commence. Once the flow reaches a predeterminedlimit, the blower will be modulated to correspond to the flow demand.During periods of transience in flow, where the blower may be slow torespond, the secondary heating element will provide instantaneous, butlimited, heat to the water.

A control output is provided to modulate the amount of fluid flowingthrough buffer tank 15. A buffer tank bypass three way valve 56 is usedto divert flow from buffer tank 15 when the demand for hot water cannotbe met by the water in buffer tank 15. The diverted water flows directlyfrom the heat exchanger to the point of demand, avoiding cooling thatoccurs upon mixing with cooler water stored in buffer tank 15. A controloutput is provided to modulate the recirculation flow rate and the flowrate through an auxiliary heat sink such as in the case of a radiantfloor heating. In situations where water is in an overheated condition,an auxiliary heat sink can help achieve a specific water temperatureoutput by diverting excess thermal energy to an auxiliary heat sink.

A control output is provided to modulate the flow magnitude through theinternal and/or external recirculating flow circuits 25, 27. Theplacement of pump 28 in the main flow path enables one or both of therecirculating flows.

FIG. 3 depicts a controls diagram for the current invention. It is to beunderstood that even though not all inputs are shown for each controlportion, it is the intent of the inventors that one or more of theomitted inputs may be used in the control system. The current diagram asit is shown represents a simplified controls diagram depicting majorcontrol inputs affecting each control portion. The rate of change ofeach input is also omitted since time domain is inherent in any controlsystems.

Referring generally to FIGS. 1 and 2, and more particularly to FIG. 3,the outlet water temperature is controlled by varying the output of flowlimiting valve 24, primary heating element 9, secondary heating process17, pump 28 and three way valve 56. Primary heating element 9 representsthe heat source provided by the combination of a blower 36 and a burner34. Controller 38 comprises several distinct control portions. Eachcontrol function 90, 92, 94, 96, 98, 100, 102 is depicted in a distinctblock diagram in FIG. 3. Each controller 38 within a control portionrepresents a control methodology responsible for driving one or morehardware components. Each control methodology can include a controlmethod such as a Proportional Integral Derivative (PID) control or acomponent of this control method such as the Proportional portion, theIntegral portion, the Derivative portion or any combination of thesecomponents. Each control methodology can also include a fuzzy logiccontrol. The output of each control portion contributes to the waterheating rate of the water heater 2 and therefore the outlet temperature70.

In the exemplary embodiments, the control system includes main control94 which is responsible for driving outlet temperature 70 quicklytowards desired temperature 74. It can be thought of as the controlportion that brings outlet temperature 70 to desired temperature 74 atsteady state. Main control 94 compares inlet temperature 72 and desiredtemperature 74 and calculates a corresponding heating control outputbased on the difference 78 in the inlet temperature 72 and desiredtemperature 74. Main control 94 also receives a flow rate 80 andcalculates a corresponding heating control output based on flow rate 80.In addition, main control 94 takes the differential pressure signal 106between the inlet and outlet flow as an indication of the presence of aflow. The magnitude of a demand is indicated by the combination of bothflow rate 80 and differential pressure signal 106. A small demand isindicated by a differential pressure only, while a large demand isindicated by a combination of a differential pressure as registered ondifferential pressure switch 104 and a flow rate as registered by flowsensor 26. As flow rate increases, the intensity of burner 34 isincreases. Conversely, as flow rate decreases, the intensity of burner34 is also decreased. Under certain conditions, burner 34 can be turnedoff. Recirculation is provided and functions to remove residual heatfrom the heat exchanger.

The control system further includes feedback control 92, which isresponsible for mitigating transience and also ensuring that outlettemperature 70 is driven towards desired temperature 74 and meetsdesired temperature 74. Feedback control 92 compares the desiredtemperature 74 and outlet temperature 70 and calculates a correspondingheating control output based on temperature difference 76 between thedesired temperature and the outlet temperature.

The control system further includes feedforward control 90 which isresponsible for mitigating transience and also ensuring that outlettemperature 70 is driven towards desired temperature 74 by applying aheating control output based on outlet temperature 70. Feedforwardcontrol 90 receives the outlet temperature 70 and calculates acorresponding heating control output based on the magnitude of outlettemperature 70.

The control system further includes recirculation control 100 whichcomprises an internal recirculation control and external recirculationcontrol features. Internal recirculation control is primarily used formitigating transience and aids in mitigating freeze hazards. Externalrecirculation control eliminates the issue related to the cold columntrapped between the heater and a point of demand. Additionally, externalrecirculation functions to reduce the delays associated with supplyinghot water from the heater to a point of demand. Recirculation isprovided by a pump 28 in combination with either internal modulatingvalve 35 or external 37 modulating valve, and is used when a buffer tank15 flow exists as permitted by buffer tank bypass three way valve 56.When outlet temperature 70 approaches substantially the merged flowtemperature 41 as measured by temperature sensor 39, recirculation isturned on in conjunction with buffer tank 15 to avoid potentialovershoot in the situations where flow rate is suddenly decreased orstopped.

The control system 102 further includes a flow limiting valve and anavailable power 112 calculator, the calculator provides an estimate ofavailable power based on the sum total of the power ratings of each ofthe system's heat sources. The power requirement is the power requiredto take the water with a flow rate 80 from an input temperature 72 to adesired temperature 74. If the power requirement exceeds that of theavailable power calculated by available power 112 calculator; controller38 calculates a flow rate which would result in a power requirementmeeting the available power 112 and controls the flow limiting valve toprovide this flow rate.

The control system further includes a buffer tank bypass three way valve56, wherein the valve provides the ability to meet a user demand in thesituation where the temperature at buffer tank 15 or at the outlet isnot sufficiently hot. Controller 38 determines whether outlettemperature 70 is high enough to meet a user demand by comparing thedesired temperature to the outlet temperature 70 and buffer tank 15temperature. If the desired temperature is higher than either the outletor buffer tank 15 temperature, the controller further determines whetherbuffer tank 15 flow needs to be reduced. If the outlet temperature islarger than buffer tank 15 temperature, the valve port connected tobuffer tank 15 will be closed or reduced effectively closing or reducingbuffer tank 15 flow and the valve port connected to buffer tank bypassline 45 will be opened or increased in order to divert all or allowlarger flow through buffer tank bypass line 45. By bypassing buffer tank15, all heated water is delivered directly and expediently to firstdemand point 66 without having been mixed with cooler water in buffertank 15. As a demand persists, bypass flow 44 will be graduallydecreased and buffer tank flow 54 increased so as to increase theability of the heating system to handle transience as buffer tank 15will store sufficient heated water to buffer any temperaturefluctuations due to a sudden increase or decrease in demand.

FIG. 4 depicts an alternate embodiment of water heater 2 configured toprovide hot water for a variety of applications. In this embodiment,water heater 2 is connected to a second demand point 68 via an auxiliarythree way valve 59. A second outlet temperature sensor 23 provides watertemperature at second demand point 68. In this configuration, heatedflow 13 is mixed with inlet flow cold water to achieve a desiredtemperature specified for second demand point 68. Mixed flow 21 tosecond demand point 68 is a merged flow of heated 13 and cold waterinlet flow. Controller 38 determines the positions of three way valve 59ports for mixing the correct amounts of heated and cold water to achievethe desired temperature. The need for having an additional water outletat distinct temperatures is solved by providing a three way mixing valveand a temperature sensor operably connected to water heater controller38. The temperature to each water outlet is user definable. For example,the water line connected a dishwasher could be set to 140 degreesFahrenheit while the water line connected to a shower could be set at105 degrees Fahrenheit and the water line connected to a hydronicheating system could be set at 160 degrees Fahrenheit.

Referring again to FIG. 4, an external auxiliary device circuit 19 isprovided. In this embodiment, auxiliary heat sink 64 (e.g. a radiantheat coil), incorporates a modulating valve 47 wherein modulated heatedflow 13 is externally recirculated with the aid of pump 28 and returnedvia internal recirculation flow 32. In cases where cold water column atfirst demand point 66 is a concern, such external configuration may alsobe used to recirculate heated water to first demand point 66 placed atgreat distance from water heater 2. The problem of long delays to gethot water to the first demand point 66 due to cold water being presentin the lengths of pipe between the water heater and first demand point66 is solved by providing pump 28 to enable external recirculation.Additionally, external auxiliary device circuit 19 can be used tointroduce heated water into the hybrid tankless water heating systemderived from alternate energy sources such as solar energy, geothermalenergy, microwave energy, electric energy, or the like.

FIG. 5 depicts another way a heat sink may be connected. In thisembodiment, a heat sink such as a radiant heat coil is connected tointernal recirculating flow circuit 25. This embodiment provides lessflexibility in controlling the heat sink flow since auxiliary heat sink64 flow is also internal recirculation flow 32.

Now that an exemplary embodiment of the present invention has beendescribed, focus will be turned to a discussion of the novel featuresand advantages provided. Many drawbacks and limitations of the prior arthave been overcome by the present invention.

By placing buffer tank 15 downstream from the primary heat exchangervariations of actual outlet temperature from a desired outlettemperature can be reduced. Referring to FIG. 1, buffer tank 15 receivesheated water at its inlet from the exit port of the heat exchanger thatis receiving heat from a burner 34. In one mode of operation, the waterflowing through buffer tank 15 is delivered to first demand point 66. Inanother mode of operation, a portion of the water flowing through buffertank 15 is delivered to first demand point 66 and the remaining portionis recirculated to the inlet of the water heater. The recirculated wateris merged with incoming cold water at the inlet, resulting in a flowinto the heat exchanger that is at a higher temperature than theincoming cold water. The water temperature exiting the heat exchangercan fluctuate due to variable heat rate provided by burner 34 duringoperation. When the water flow with fluctuating temperature enters thebuffer tank, the incoming flow mixes with the existing buffer tank 15water, thereby lessening the impact of any sudden changes in temperatureof the incoming flow and resulting in water flow that is more uniformover time.

The current buffer tank 15 placement differs from prior art water heatersystems where buffer tank 15 is mounted upstream of the heat exchanger.In the prior art configuration, a forced recirculation is necessary toeffectively mix a heated flow with the cold incoming water,necessitating the utilization of a recirculation pump. Since buffer tank15 is placed downstream from the heat exchanger in the currentinvention, no forced recirculation is necessary to realize the benefitof buffer tank 15 during portions of the water heater operation. Thus,the problem of minimizing variation of actual outlet temperature from adesired outlet temperature in a fluid control system is solved bydisposing a buffer tank 15 downstream of the heat exchanger in a fluidheating system.

Another drawback with current on demand water heaters is an undesirableand inconvenient delay for the user to receive water in the desiredtemperature range. The delay associated with obtaining the hot water atthe desired temperature is related to the temperature of the cold waterinput feeding the water heater. The delay can be attributed to thecorresponding heat transfer from the burner to the contained waterlocated within the heat exchanger tubes. A byproduct of the delayresults in a user avoiding the cold initial water flow resulting inwaste of both time and water. By way of illustration, most users takinga shower will wait to commence use of the water until the temperaturereaches (increases to) a certain comfortable range. The flowing water,as well as the user's time, is wasted as the cooler water flows down thedrain waiting for the flowing water to reach desired or targettemperature.

A second heating source, when placed inside a reservoir of water such asthe stored water in buffer tank 15, enables the water heater to quicklymeet the sudden increase of a sizable hot water demand by quicklyraising the water temperature in buffer tank 15 so that water can bedelivered to the user at desired temperature. In one embodiment, animmersion electric heater is used as secondary heating element 16. Asecondary heating element 16, e.g. an electrical heating element,transfers heat by conduction to the water surrounding its coil. Unlike aburner-heat exchanger arrangement, the heating source of secondaryheating element 16 comes in direct contact with the water and cantherefore transfer heat more efficiently to the water.

A second heating source also provides fine heating modulation which islacking in a primary heating source. Fine tuning the outlet fluidtemperature is achieved by providing primary heating element for coarseadjustment to the inlet fluid temperature and further providing asecondary heating element for fine adjustment to the inlet fluidtemperature.

Overshoot in outlet temperature response is minimized by providing asecondary heating element 16 with variable heating power at low heatingrate, and/or a mixing valve and/or a capillary bypass line 60. By way ofillustration, the secondary heating element 16 (e.g., electric heatingcoil) is used where ambient temperature is over 70 degrees F. Primaryheating element 9 (e.g., burner) provides coarse adjustment andsecondary heating element 16 provides fine adjustment to the inlettemperature. A decrease in demand causes excess heat stored in the heatexchanger tubes to be transmitted to the fluid due to the temperaturegradient favoring heat transfer from the tubings to the fluid. Buffertank 15 holds ample amount of water to be recirculated in order todissipate the excess heat once heating has ceased. A mixing valve mixesoverly heated fluid with fluid at a lower temperature, quickly reducinga potential overshoot in the outlet temperature to a safe temperature.

Capillary bypass line 60 operably connecting the cold fluid inlet andthe hot fluid outlet allows fluid flow from the high pressure side(i.e., cold side) to the low pressure side (i.e., hot side) causing theoverly heated fluid to be mixed with the colder fluid.

Delayed temperature response is also minimized by proactivelymaintaining the outlet temperature during pre-set periods of water usageor predicted periods of water usage. In the present invention, there areset time periods in a day at which the outlet temperature will becontrolled to the desired temperature to avoid both firing and transientdelays. During these periods, the water will be heated, stored in thebuffer tank and recirculated. The user may preprogram periods of a dayin which high water usage is expected via user interface 43. The usermay also select a mode where the controller, through collection andanalysis of water usage data over a period of time, automaticallydetermines periods of high usage and maintain outlet water temperatureat desired temperature.

When a water demand detected, delayed temperature response is solved byproactively recirculating fluid for initiating the primary heatingelement. The rapid detection of a growing demand by differentialpressure switch 104 causes burner 34 to turn on even when the flow (saybetween 0.005 and 0.5 gpm) has not risen above the flow sensor 26detection threshold (typically 0.5 gpm), thereby shortening the time ittakes to achieve the desired outlet temperature.

Current tankless water heaters start controlling to desired temperatureby detecting a flow condition. Typically, a minimum flow threshold of0.5 GPM is required to turn on the burner. If a demand fluctuates aboveand below the minimum threshold, the water will be heated only duringportions of the demand resulting in water temperature not meeting thedesired temperature. In order to detect a small flow, a prior art methoduses a difference in temperature between the inlet and outlet ports of abuffer tank 15 or the rate of drop of the inlet port temperature andoutlet port temperature to indicate a flow condition. The use of thisindication may be erroneous since the temperature differential betweenthe inlet port and outlet port of buffer tank 15 does not necessarilyindicate a flow demand. Another prior art method to detect that a demandexists in a buffer tank involves sensing the temperature drop in eitherthe inlet port or outlet port. This method often results in erroneousdemand indication. Therefore, utilizing these indicators may cause thewater heater to warm the tank water unnecessarily.

Typically, a minimum flow threshold of 0.5 GPM is required to indicate ademand to cause the burner to turn on. In prior art tankless waterheaters, since water is heated only when the minimum flow threshold ismet, there will be no heating when the flow demand does not rise abovethe minimum threshold. This flow condition below the minimum thresholdis called the dead zone. In the present invention, a small flow isdetected using a differential pressure switch 48, wherein the switch iscapable of detecting a flow greater than 0.005 GPM. The detection of asmall flow causes secondary heating element 16 to turn on, therebykeeping the outlet water warm. Thus, the problem of dead zones is solvedby utilizing a differential pressure switch capable of detecting a smallflow for initiating a heating element.

Variance between desired outlet fluid temperature and actual outputfluid temperature is reduced by providing supplemental heat via asecondary heating element 16. The need to respond quickly to a hot waterdemand causes the controller to fire the burner at high rate in order tomeet a heating demand. Firing the burner at high rate causes water towarm up quickly. However, the heat exchanger tubing material can storeexcess heat and reach a high temperature. When the desired temperatureis about to be reached, the burner is turned off to avoid or reduceoutlet temperature overshoot. If the burner is turned off too early, theoutlet water temperature will not reach the desired temperature quickly.If the burner is turned off too late, the risk of overheating the wateris greater. Even after the burner is turned off, the excess heat storedin the heat exchanger continues to cause a positive temperature gradientbetween the heat exchanger tubes and the water flowing through them,thereby causing the heat exchanger to maintain the previously inducedburner heating rate even while the burner has now been turned off. Ifthe outlet water temperature can no longer meet the desired temperature,the burner is again turned on. This frequent turn-on and turn-off of theburner causes the undesirable phenomenon called hunting, i.e., theoutlet temperature fluctuates about the desired temperature even insteady state. With the use of secondary heating element 16 (e.g.electric heating element) in conjunction with burner 34 (primary heatingsystem 8), water heater 2 can react quickly to a water demand by firingburner 34 to heat the inlet water quickly while reducing overshoot.Secondary heating element 16 is capable of providing a small heat ratethat complements the heat rate produced with normal burner 34 operationand pulse firing of burner 34. Secondary heating element 16 minimizesthe need for burner 34 to take the outlet temperature very close to thedesired temperature before turning off and thereby overcomes temperatureovershoot. The problem of excessive heating control hunting especiallyduring periods of trickle or low flows is solved by providing asecondary heating element 16 or pulse firing of primary heating element9 for fine control of outlet fluid temperature and a means for selectingwhether to initiate primary heating element 9, a secondary heatingelement 16, or combinations thereof.

In prior art water heater systems, a cold sandwich effect occurs when auser briefly turns off a faucet that has been running water of desiredtemperature for an extended period of time. This brief cessation ofdemand creates a column of scalding hot water resulting from excess heattransferred to the small quantity of water remaining in the water heaterfrom the heat exchanger thermal mass upon shutting down burner 34.Responding to this high outlet temperature, the controller ceases toprovide more heat to the water causing a trailing column of water to beunder heated. Eventually when the outlet temperature sensor startsdetecting this cold water column due to a resuming demand, heatingresumes and a steady state flow with desired temperature is achieved.The problem of the cold sandwich effect in a transient system is solvedby recirculating the small quantity of water remaining in the heatexchanger upon cessation of a demand via the buffer tank. Recirculationcauses excess heat to be dissipated and distributed more uniformlythroughout the remaining volume of water in the water heater. When ademand restarts, recirculating via buffer tank 15 causes the colderincoming water to be mixed with existing warmer water in the buffer tankto yield water at more uniform temperature over time.

Legionnaire bacteria grow well in stagnant water of from 80 to 120degree Fahrenheit. Recirculation of outlet flow and maintaining watertemperature at elevated temperature of 140 deg Fahrenheit aids ineliminating this dangerous bacteria. In the current invention, the waterheater can be programmed to turn on periodically. Recirculation causesheat sources to turn on in order to maintain the outlet temperature atthe desired temperature. Thus, the problem of bacteria growth in storedwater supplies and water system components is solved by recirculation ofoutlet flow and maintaining water temperature at elevated temperature of140 degrees Fahrenheit.

In the current invention, an unconventional heat exchanger is used. Theburner 34 is inverted and placed above the heat exchanger tubes in aburner cavity. When the fuel supply line is opened, the blower blowsair-fuel mixture down towards the heat exchanger disposed below theblower nozzle. As such, the flue gas has the tendency to rise and itmust be forced down towards the heat exchanger by a blower. The heatexchanger is an array of tubes where the heat provided by burner 34 istransferred to the water flowing in the tubes. The heat exchanger isconfigured such that the exiting water flow portion is disposed closestto burner 34 and the incoming water flow portion is disposed mostdistant from burner 34.

Prior art tankless water heater systems do not provide for an alternatepower source during primary power outage. In the current invention, analternate power source is provided and automatically sourced should aprimary power loss to the water heater system occur. Thus, a preferredembodiment provides and automatically sources a secondary onboard energysource such as a backup battery or an inline hydro generator capable ofgenerating electrical power from hydraulic power. By continuouslyproviding power to the water heater in the event of a primary powerloss, freeze protection is provided, giving enough time for the user toeither drain the water heater system or provide additional andcontinuous backup power. In addition, continuous operation of the waterheater system also allows for temporary hot water usage.

The problem of overheating (temperature spikes) of water during a rapidreduction (step down and completely off) in demand is solved by activelyre-circulating the water, cutting down heat input, and in some cases byturning the blower to a maximum speed without flame. This is achieved bydetecting a change in flow demand, starting the recirculating pump,lowering or shutting off firing of the burner and turning on the blower.Thus, transient temperature spikes are reduced by means of controlling ablower that can optionally operate independent from the burner and arecirculation pump.

In the current invention, detection of a leakage between the water inletand water outlet of the water heater is accomplished with a moisturesensor that alarms when excessive moisture is detected in the cavity ofthe fluid heater inside the water heater enclosure. This sensor iscapable of sensing a leak that occurs within the water heater enclosure.

In the current invention, leakage from external plumbing operablyconnected to the water outlet is detected and/or ceased by providing adifferential pressure switch operably connected to the inlet end andoutlet end of the water heater. This differential pressure switchdetects a small flow condition by registering a pressure differentialbetween the two ends of the water heater over a period of time. If thisperiod exceeds a preset leak time threshold, a leak condition is raisedand a warning is issued to the user and/or the flow control valve ismoved to the closed position.

In the current invention, a small leak or an open faucet for longperiods of time will be detected via a pressure difference as registeredby a pressure differential switch over an extended period of time asspecified by the user. For example, a continuous detection of a pressuredifference over a period of 30 minutes may indicate a leak.

In the current invention, detecting leakage downstream of the flowsensor is achieved by providing a flow sensor to detect the actualamount of flow and compare such actual amount of flow to a knownquantity of water programmed to be delivered such that when thedifference exceeds a predetermined fault threshold, a leak condition israised. Upon detecting a leak condition, a warning is issued to the userand the flow limiting valve is shut to stop further water loss.

Freeze hazards are minimized in the present invention by periodicallymaintaining water temperature at a level higher than the freezing point.The current invention periodically recirculates flow even without anexternal user demand. This recirculation may occur at preprogrammed orlearned usage periods and monitoring the heater inlet and outlettemperature or their rate of change such that when the outlet or inlettemperature drops below a certain threshold, or if the rate oftemperature drop exceeds a certain threshold, recirculation and/or asecondary heating element 16 is initiated. Similarly, when the outlet orinlet temperature drops below a certain threshold or if the rate oftemperature drop exceeds a certain threshold, a secondary heatingelement 16, combined with pulse firing of primary heating element 9, aswell as recirculation, are initiated.

Detecting trickle flow or low flow at any given time is accomplished byusing a differential pressure switch. A differential pressure switch isoperably connected to inlet 10 and outlet 12 ends of the water heater.The switch is in the off position when there is no flow in the waterheater. A flow in the water heater creates a pressure differentialbetween inlet 10 and outlet 12 ends, thereby moving the differentialpressure switch to the on position. The pressure differential switch ispreferably capable of detecting flow greater than 0.005 gpm or a rangeof flow not detectable in a flow sensor.

Prior art buffer tank 15 temperature based water heater control systemsrely on the temperature difference between buffer tank 15 inlettemperature and buffer tank 15 outlet temperature to indicate a need toturn on a heat source. In the present invention, the entire range offlow demand is detectable by using the differential pressure switch andthe flow sensor. Since the temperature difference between buffer tank 15inlet and outlet is not required, only one temperature sensor isrequired for buffer tank 15, provided that inlet buffer tank 15 flow ismixed well to yield a uniform water temperature throughout buffer tank15. This provides an advantage over the prior art using multipletemperature sensors in the controls scheme. Temperature variationswithin buffer tank 15 are minimized by having baffles or a barrel-holestyle inlet system for creating turbulence which promotes mixing of theincoming water with existing water in the tank, enabling the use of asingle temperature sensor representative of the entire buffer tank 15temperature.

In the prior art, the need for a forced recirculation is indicated by adrop in the buffer tank inlet temperature. In this prior artconfiguration, heating is tightly coupled with the presence of arecirculating flow and heating would not occur until force recirculationhas been activated. In the present invention, no forced recirculation isnecessary to initiate heating. When a demand exists as indicated by thedifferential pressure switch and the flow sensor, a high firing rate ofburner 34 combined with recirculation, meets the hot water demand in ashort time without having to unnecessarily warm water stored in buffertank 15 for an extended period of time. Thus, the problem of longduration necessary to heat up water to the desired temperature is solvedby actively recirculating the water and by deliberately increasing theheat input (higher firing rate) for a predetermined duration upondetecting a flow demand. This provides a significant advantage over theprior art since temperature control is enhanced during transience andstartup flow conditions.

In systems relying on the water temperature in buffer tank 15 as aleading indicator to trigger heating, much of the heating is wasted whenthere is no actual demand. However, with a system relying on thedifferential fluid pressure between the inlet and the outlet ends andflow sensor to indicate demand, heating would commence only when thereis an actual flow unless it is programmed to do so otherwise. Also,temperature is a lagging indicator in that it takes longer fortemperature to change to indicate a change in demand whereas a heatingsystem based on the presence or magnitude of a flow indicates a changein demand immediately so that this change can be acted upon immediatelythereby improving the heating response time. Thus, the goal ofmaintaining outlet temperature is achieved by using a differentialpressure and a flow rate as leading indicators in the present invention.

When hot water is first requested, a motorized three way valve closesthe flow path to the buffer tank, thereby bypassing it and diverting allheated water to the point of use. As the burner keeps up, the three wayvalve slowly diverts the flow through to buffer tank 15 and maintains aportion of the flow in the bypass line. Thus, the long durationnecessary to heat water to the desired temperature is eliminated bybypassing the buffer tank 15 during startup and increased demands sothat undiluted hot water can be delivered to the point of use withouthaving been mixed with cooler water in the buffer tank.

Water hammer occurs when a user suddenly ceases water demand by closinga valve creating pressure surges. A capillary bypass line 60 can absorbthe pressure surges, mitigating the damaging effects of water hammer.Thus, the problem of high pressure spikes is minimized by using adedicated capillary bypass line 60 operably connected to the inlet andoutlet ends of the water heater.

The minimum power output of burner 34 is typically 20,000 BTU/hour (witha modulation range of 10:1 (turn down ratio) and a burner size of200,000 BTU/hour). In order to achieve a lower average power output,pulse firing is used. In pulse firing, the burner power is modulatedsuch that in a pulse cycle, burner 34 is turned on for a preset durationand turned off or turned down to a lower setting for another presetduration. The average power is the average power of each cycle. Thus,the problem of inadequate low firing rate or minimum firing rateconstraint is solved by pulse firing burner 34 (with constant bloweroperations).

As the water heater ages, various components of water heater 2 may breakdown and require repair or replacement to ensure proper operation ofwater heater 2 and to avoid safety hazards. Scaling may develop in theinterior surfaces of the flow tubes of water heater 2. Inadequaterecirculation can be a sign of pump breakdown. The ability to detect afailed pump is provided by detecting excessive flue temperature and fluetemperature rise rate. This provides a significant advantage over theprior art. A service alert can be issued when such a condition isdetected. Thus, pump failure or inadequate re-circulation flow isdetected by monitoring the flue out temperature and its rate of changeto proactively managing the heat input (e.g., powering off the unit).Additionally, the problem of degraded heat exchanger performance isdetected by monitoring the flue out temperature and its rate of change,buffer tank or outlet water temperature to proactively inform user tointervene. Under normal operation, the heat provided by the burner isproperly transferred to and absorbed by the water flowing through thewater heater. Since a good portion of provided heat is recovered, theflue gas temperature should not be excessively high. The flue ventmaterial is protected by monitoring the flue gas temperature and itsrate of change to proactively manage heat input.

Most modern water heaters are designed without providing the user orservice personnel serviceability. Poorly maintained water heater mayneed to be replaced prematurely. In the present invention,serviceability is facilitated. Hard water causes unwanted mineraldeposits (scaling) on the fluid contact surfaces of the water heatersystem. Severe scaling can cause severe drop in the water heaterefficiency and life span. Scale deposits in the interior surfaces ofheat exchanger tubes can reduce the heat exchanger efficiency as thescale deposits reduce heat transfer rate from the exterior to theinterior surfaces of the heat exchanger tubes. Therefore, more heatwould be required to raise each degree of water temperature. Excessivescale deposits, or any other like issues, that cause reduced heatexchanger efficiency, can lead to overheating of the exterior surfacesof a heat exchanger resulting in a shortened heat exchanger servicelife. In addition to resulting in damage to the heat exchanger,overheating of the heat exchanger exterior surfaces leads to undueenergy loss. The problem of overheat and heat loss of the exteriorsurfaces of heat exchanger is solved by providing at least a baffle or astructure capable of swirling or mixing pre-combusted air (as providedby blower 36) in the vicinity of the heat exchanger, thereby promotingheat transfer from the exterior surfaces of the heat exchanger to thepre-combusted air and recovering this absorbed heat of the pre-combustedair by redistributing it to colder portions of the heat exchangersurfaces.

There is provided a service access to the hot water system such that acleaning agent may be introduced in the recirculation circuit and adedicated service mode such that the recirculation pump may be activatedwithout turning on any heat sources. The prior art does not provideend-user direct access such as this, rather, requires a trainedmaintenance person to perform such tasks by at least partially takingapart the water heater.

When a problem occurs, a typical water heater diagnostic system providesrudimentary information in the form of fault codes which require furtherdecoding for corrective instructions. A novel feature of the currentinvention enables an end user of the current water heater to takeappropriate steps by providing not only fault codes but also correctiveinstructions associated with the fault codes. As such, the end user iscapable of taking corrective actions without having to wait for servicepersonnel or resort to an instruction manual. In one embodiment, a faultcode is decoded by providing speech capability to the water heater, ameans of transmitting a spoken fault code by phone to a fault codedatabase, a means for identifying the problem source and its associatedcorrective procedures based on the transmitted fault code and a meansfor notifying the user of the corrective instructions. In anotherembodiment, a fault code is decoded by automatically transmitting afault code via internet to an off-site database, retrieving correctiveinstructions based on this fault code, and notifying the user ofcorrective instructions with text or audible speech instructions.

In the current invention, active and continuous monitoring performanceand health of the water heater minimize unforeseen service outages. Inone aspect, the controls provide for automatic adjustment of operatingparameters based on measured performance. Performance is determined bylogging blower rpm, power output and comparing them to nominal valuesand the water heater's historical data. Additionally or alternatively,prognostic feedback is provided to the user so that a water heaterproblem can be responded to before a break down can occur. In the eventa problem is so severe that it cannot be corrected automatically, theuser is timely alerted.

In a condensing heat exchanger, a drip collection pan is used to collectthe condensate which is in turn drained with or without pressure assistvia a drainage tube to a sump. A blockage in the drainage tube can causebackup or overflow of the condensate and cause corrosion in water heatercomponents exposed to this condensate. A condensate level sensor 50provides alert and calls attention of the user that condensate drainageis blocked and requires attention. A small pump may also be used to aidcondensate drainage. In the case a small pump is used, the need forgravity drainage is unnecessary and therefore the need to mount thewater heater at an elevated position to create this gravity drainage iseased. Thus, the problem of flue condensate backup or blockage isdetected by using condensate level sensor 50.

Flow sensor 26 as used in this invention is connected to the inlet ofthe water heater and therefore does not experience elevated temperature.As such, it does not require a more expensive high temperature gradeflow sensor. By mounting the flow sensor outside of the recirculationcircuit, there is no pressure loss imparted by the flow sensor. Thisallows the use of a pump with a lower power rating, thereby making thewater heater more economical. Additionally, no proprietary valves arerequired.

When a user first enters a shower, the user may be initially satisfiedwith a water temperature that is higher than the ambient airtemperature. The user will likely demand progressively hotter water asthe shower progresses due to user temperature acclimation. Normally, auser demands hotter water by manually increasing the valve controllingthe hot water supply. The present invention optionally includes afeature that allows the user to set an automatic temperature rise rateand a high temperature limit that aligns with the user's temperaturerate of change profile or acclimation profile; thereby providing avarying temperature service. For example, the initial requestedtemperature is 90 degrees. The user may choose to increase the watertemperature by 1 degree per minute. If the demand is left untouched, thewater temperature would be increased to 95 degrees in 5 minutes ofusage. If the high temperature limit is set at 92 degrees, the watertemperature would be increased only to 92 degrees in 2 minutes andremains at that temperature throughout the rest of the duration of thedemand.

Automatic faucets have been in widespread use for some time. In anautomatic faucet system, a proximity sensor is used to detect thepresence of a demand. When a user approaches the faucet with his or herhands extended into the field of view of the proximity sensor, thefaucet is automatically turned on and water is automatically discharged.This will trigger external or even internal recirculation, thus“preparing” the water heater to be ready for anticipated water use.Proximity sensors here are used to detect the presence of a person inthe bathroom, sending a signal to the heater and preparing the heaterfor hot water use.

Natural gas is an energy source or fuel commonly used in residentialhomes, businesses, as well as industrial settings, appliances andsystems that operate on natural gas include HVAC systems, kitchenstoves, clothes dryers, water heaters, and the like. The number ofnatural gas devices that can be powered simultaneously is a function ofthe utility natural gas service line(s) maximum capacity compared to thesum of the gas usage rates of the individual devices. A natural gasover-demand situation occurs when the cumulative sum of usage rates fromeach of the operating natural gas appliances or devices is greater thanthe maximum capacity of the incoming natural gas service utility line orlines. During such a natural gas over-demand situations, it's common toengage a device's fail-safe system. System fail-safes include flameoutor other type of natural gas shut down type routines resulting frominadequate natural gas supply or gas starving.

In one embodiment of the present invention, the undesirable gasover-demand type situations are avoided or reduced in frequency inhybrid tankless water heating systems by utilizing a modulating gasburner where the natural gas consumption rate is reduced, or de-rated.This reduction is accomplished via the modulation of a modulating gasvalve and cooperating blower. Controlling the heater in such a manner,results in the reduction of natural gas usage or consumption rate andassociated reduction in blower speed by predetermined levels dictated bya controller. The typical hybrid tankless water heating system includesa blower, a burner, and a buffer tank having an auxiliary heating meanshaving an energy source other than natural gas along with supportinghardware. Supporting hardware includes at least one natural gas pressuresensor, can be a hardwired element as well as a wireless version, thatis located upstream or in the gas feed line of the hybrid tankless waterheating system, and a controller to enable cooperation among the varioussystem elements. Alternatively, a network of gas powered devices canrelay their status including usage rates to a controller therebycreating an alternate embodiment without the need for a natural gaspressure sensor (since available gas capacity can be calculated).

In a typical configuration, the natural gas pressure sensor is used todetermine the real time natural gas available to the hybrid tanklesswater heating system, and in conjunction with a controller, is used todetect a natural gas over-demand situation. If such a natural gasover-demand situation is detected or predicted, the controller reacts byde-rating the burner and blower subsystem of the hybrid tankless waterheating system. Given a particular natural gas input line geometry (e.g.round pipe inner diameter); maximum flow rates are easily calculatedalong with corresponding heat output.

Another variation of the present embodiment under discussion is the useof two or more external gas usage sensors or monitors each having aninput signal to the controller that provides an indication as to whetheror not the gas supply is shared among gas consuming appliances, enablingthe calculation of the real time gas supply rate available. If it isdetermined that the utility natural gas service line is shared by one ormore gas consuming appliance, the water heater burner will be de-ratedif a natural gas over-demand situation is detected or predicted bylimiting the gas valve opening to align with the actual gas supplyavailable at that moment. By having a more accurate burner heat outputprediction, the controller is better able to determine whethersupplemental heat via the buffer tank to compensate for the reduction ofnatural gas should be used. In one embodiment, the external gas usageinput receives gas pressure sensor measurement from the gas supply line.In another embodiment, the controller wirelessly receives one or moresignals indicating the corresponding pressure drop, usage rates, or thelike of the other appliance(s) sharing the same gas supply line.

The typical method for reducing natural gas consumption in a hybridtankless water heating system to avoid a natural gas over-demandsituation comprises continuous monitoring of available natural gaspressure along one or more portions of the natural gas distributionnetwork monitoring for potential natural gas over-demand situations. Ifsuch a natural gas over-demand situation is detected, a controllerreduces the burner natural gas consumption rate and speed of thecorresponding blower by predetermined levels such that natural gasconsumption rate of the hybrid tankless water heating system avoids theundesirable natural gas over-demand situation.

The following example provides a more detailed analysis of oneembodiment. The embodiment includes a modulating gas burner wherein thesupply of gas is modulated by adjusting a modulating gas valve connectedto the modulating gas burner. Referring again to FIG. 2, there isfurther provided an external gas usage input signal 53 which correspondsto the rate at which the gas supply is used by external gas consumingappliances such as a furnace. In a typical operating environment, theremay be multiple gas consuming appliances, such as a gas furnace, radiantfloor heater and water heater burner which source gas from the same gassupply. If all appliances are operating at their respective high ormaximum capacities, a condition may exist where the gas supply isincapable of supplying gas to all appliances at normal operatingpressure. Under such condition, one or more appliance is said to bestarving for gas wherein the actual gas supply rate is below theexpected amount. There exists a need in modulating gas supply to thecurrent burner such that the heat output corresponding to the gas supplyis quantifiable. The external gas usage input signal 53 provides anindication as to whether or not the gas supply is shared amongst gasconsuming appliances and/or what gas supply rate is available. In oneembodiment, such indication is provided by a gas pressure reading thatis lower than a predetermined level. Upon determination of a shared gassupply, the water heater burner will be derated by limiting the gasvalve opening to better reflect the true heat output corresponding tothe gas supply. By having a more accurate burner heat output prediction,the controller is better able to determine whether supplemental heat isnecessary. In one embodiment, the external gas usage input receives gaspressure sensor measurement from the gas supply line. In anotherembodiment, the external gas usage input receives a signal indicatingthe rate or the presence of gas usage of a second appliance sharing thesame gas supply. In one embodiment, the external gas usage input isreceived wirelessly.

When a hybrid tankless water heating system is initially turned on orwhen a water demand is abruptly increased, there is an initial warm upperiod where the burner-blower subsystem has to get the heat exchangerup to a temperature that will yield output water flow at the targetpredetermined temperature. During this warm-up period, if hot water isrequested, the temperature of the output water flow will be lower thanthe desired target predetermined temperature, thus creating undesirablecold water transient.

In one embodiment of the present invention, the length of time orduration associated with undesirable cold water transient is reduced bythe incorporation of a water flow limiting valve and a controllerfunctionally connected to said water said water flow limiting valve.This is accomplished by restricting the water flow through the hybridtankless water heating system or water heater, thereby enabling thedelivery of water at the predetermined temperature at a reduced flowrate. Supporting hardware includes at a minimum, an output temperaturesensor located at the output of the hybrid tankless water heater formeasuring an output temperature, an input temperature sensor located atthe input of the hybrid tankless water heating system for measuring aninput temperature, a flow sensor for measuring a flow rate requested ofsaid hybrid tankless water heating system and a controller fordetermining an operating capacity corresponding to the differencebetween the predetermined temperature and the output temperature, thedifference between the output temperature and the input temperature andthe flow rate. As a demand capacity increases abruptly, the flowlimiting valve is restricted to reduce flow rate such that the outputwater predetermined temperature is quickly achieved. As the waterheater's operating capacity becomes more readily available, the settingof the water flow limiting valve is adjusted such that higher flow ispermitted while the output water is maintained at the predeterminedtemperature.

An example of the aforementioned flow rate follower function isdescribed in the following sample scenario having a given input or inletwater pressure. In this example the target water flow is 5 gpm atpredetermined target temperature. Initially, the water flow limitingvalve is set to a predetermined position that is less than its maximumsetting, to enable a predetermined flow rate of 3 gpm. As the waterheater output temperature nears or attains a steady state condition, thewater flow limiting valve gradually opens allowing additional waterflow. This occurs as a result of the burner-blower subsystem heating theheat exchanger up to a temperature, or thermal capacity that is capableof delivering output water at a higher flow rate at the predeterminedtarget temperature. An initial flow represented by t=0 is set at 3 gpm.Then at time t=1, the valve opens further to allow flow up to 4 gpm(valve restriction is decreased to allow more flow). Finally at timet=2, the flow is increased to 5 gpm (valve restriction ceases allowingfull flow). It is understood that steady state conditions are achievedat both t=1 and t=2 time intervals. This allows for the heatexchanger-burner blower system to catch-up to the heat demand whilemaintaining the desired outlet temperature since the burner cannotinstantly achieve the desired thermal output.

When a hybrid tankless water heating system is initially turned on, thesystem selects one of a number of default operating points; theoperating points include burner heat output values and associatedoptimum blower speeds that are optimized for specific operatingenvironments. The default schedule of operating points is constructedwith the typical environment in mind. Situations exist where theenvironment of a specific water heater installation cause operatingpoints to deviate from their default values. In such situations, itwould be advantageous to update the schedule of default operating pointswith values better suited to the given installation environment. Thedefault value or values will only be added to, replaced and/or initiatea modification of the schedule of operating points when a new operatingpoint satisfies a schedule of operating points update criteria.

An automatic blower adjustment is a valuable feature due to installationvariations. Each installation would have specific air intake, exhaustrestriction, gas pressure variation. The blower formula included fromthe factory could be more than 10% off. Auto calibration type softwarewould use the burner heat output (mdot×Cp×delta T) and blower speedparameters to confirm or update the factory map to each specificinstall, wherein mdot is mass flow rate of water, Cp is the specificheat capacity of water, and delta T is the difference between Tinlet andToutlet. This would improve the performance of a tankless water heatingsystem, which includes improvements in transient time delays and time toreach steady state temperature conditions.

A method for updating a default schedule of operating points wouldutilize water heater operating parameters including mass flow rate,Tinlet, Toutlet, and blower speed (rpm) to run the predeterminedcomputations and create a map or an updated schedule of operatingpoints. Other conditions required to enable an update to the defaultschedule of operating points would include the attainment of steadystate conditions as it pertains to water output temperature, water flowor rate, and blower speed.

Below is an example of a factory set default schedule of operatingpoints relating burner heat output to blower speed.

Burner Heat Output (kBTU/hr) Speed (RPM) 10 900 15 950 200 5700

When a new data point that satisfies the point update criteria isidentified, the controller would modify the default schedule ofoperating points in light of the new information or new operating point;e.g. add a new data point to the default schedule or replace an existingdata point.

In one embodiment of the present invention, the schedule of defaultoperating points updating system is accomplished in a water heatingsystem having one temperature sensor for measuring water output, onetemperature sensor for measuring water input, a blower monitor fordetermining blower speed, and a controller functionally connected toeach of said temperature sensors and said blower monitor. The controllersamples the temperature sensors and monitors blower operation in searchfor an improved operating point(s) that satisfy the schedule ofoperating points update criteria. Once an operating point(s) meets orsatisfies the update criteria, the new improved operating point will beincorporated into the default schedule of operating points. Thefollowing is an example of a schedule of operating points updatecriteria algorithm:

Heat output X at a particular blower speed Y, is determined by using thefollowing formula:X=mdot×Cp×(Toutlet−Tinlet),where

mdot is the water mass flow rate,

Cp is the specific heat capacity,

Toutlet is the temperature of heated outgoing water, and

Tinlet is the temperature of cold incoming water.

X is determined using the above formula while Y is obtained by using ablower monitor. X is typically expressed in kBTU/hr units, while blowerspeed is typically expressed in rpm. The following is a tablerepresenting five operating points of heat output versus blower speed.

X1 Y1 X2 Y2 X3 Y3 X4 Y4 X5 Y5

Any new X Y pair (new operating point) is only considered forincorporation into the above table if the point reaches a predeterminedsteady state condition. Steady state condition is achieved or satisfiedwhen Toutlet, Tinlet, flow rate and blower speed have been in asubstantially steady condition for a predetermined period of time. Theterm K is defined as the variance threshold below which a new operatingpoint is used for updating the factory default table.

EXAMPLES Example 1

While water heater is in a steady state condition with conditionsX1<X<X2 and Y1<Y<Y2 being satisfied, and if the absolute differencebetween ratio (X−X1)/(X2−X1) and ratio (Y−Y1)/(Y2−Y1) is greater than K,then the proposed new operating point or pair X, Y will be discarded. Ifthe difference is less than K, then the proposed new operating point orpair X, Y will be incorporated into the factory default table. X1, Y1and X2, Y2 will be retained.

Example 2

While water heater is in a steady state condition, with conditionsX2<X<X3 and Y1<Y<Y2 being satisfied, and if the absolute differencebetween ratio (X−X1)/(X3−X1) and ratio (Y−Y1)/(Y3−Y1) is greater than K,and then the proposed new operating point or pair X, Y will bediscarded. However, if the difference is less than K, then the proposednew operating point or pair X, Y will be incorporated into the lookuptable. However, in this example, the existing X2, Y2 operating pointwill be replaced with the new operating point or pair X, Y.

It is to be understood that a plurality of methods may be employed indetermining whether an X, Y pair should be adopted.

Thus, having broadly outlined the more important features of the presentinvention in order that the detailed description thereof may be betterunderstood, and that the present contribution to the art may be betterappreciated, there are, of course, additional features of the presentinvention that will be described herein and will form a part of thesubject matter of this specification.

As such, those skilled in the art will appreciate that the conception,upon which this disclosure is based, may readily be utilized as a basisfor the designing of other structures, methods and systems for carryingout the several purposes of the present invention. It is important,therefore, that the claims be regarded as including such equivalentconstruction insofar as they do not depart from the spirit and scope ofthe conception regarded as the present invention.

The invention claimed is:
 1. A method for reducing natural gasconsumption in a hybrid tankless water heating system to avoid a gasover-demand situation, comprising the steps of: providing a hybridtankless water heating system comprising a burner having a gasconsumption rate and at least one gas pressure sensor adapted to measureavailable gas pressure supplied to the burner, measuring the availablegas pressure using the gas pressure sensor to detect a potential a gasover-demand situation by comparing the available gas pressure to apredetermined gas over-demand threshold, and reducing the gasconsumption rate of the burner by predetermined levels when a potentialgas over-demand situation is detected such that the gas consumption rateof the burner avoids the gas over-demand situation.